WO2009039386A1 - Melamine methylol for abrasive products - Google Patents
Melamine methylol for abrasive products Download PDFInfo
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- WO2009039386A1 WO2009039386A1 PCT/US2008/077036 US2008077036W WO2009039386A1 WO 2009039386 A1 WO2009039386 A1 WO 2009039386A1 US 2008077036 W US2008077036 W US 2008077036W WO 2009039386 A1 WO2009039386 A1 WO 2009039386A1
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- formaldehyde
- melamine
- melamine methylol
- methylol
- abrasive product
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/10—Metal compounds
- C08K3/14—Carbides
Definitions
- Formaldehyde is a common by product of urea formaldehyde and phenol formaldehyde based resin systems. Free formaldehyde commonly is released during the processing of such resin systems during formation of bonded, coated and nonwoven abrasive products, and may represent a potential health hazard.
- scavengers have been employed to reduce emission of free formaldehyde from urea formaldehyde and phenol formaldehyde resins.
- known scavengers the most common are polyacrylamide and urea.
- each of these scavengers cause a significant reduction in the performance characteristics of abrasive products in which they are employed.
- the invention is generally directed to abrasive products and curable resins employed to form abrasive products, to methods of forming abrasive products employing formadehyde-based resin binders having low free formaldehyde, and to methods of abrading a work piece with abrasive products employing formadehyde- based resin binders having low free formaldehyde.
- the invention is directed to an abrasive product that includes a plurality of abrasive particles and a resin binder cured from a resin composition that includes an aqueous dispersion of melamine methylol, having a pH in a range of between about 8 and about 10, and having a melamine-to-formaldehyde molar equivalent ratio of between about 1:1 and about 1 :3.2.
- the resin composition also includes a formaldehyde-based resin, such as a urea- or phenol-formaldehyde resin, wherein the melamine methylol comprises between about 1 wt% and about 50 wt% of the combined weight of the formaldehyde-based resin and the melamine methylol.
- a formaldehyde-based resin such as a urea- or phenol-formaldehyde resin
- the invention is directed to a curable resin composition that includes an aqueous dispersion of melamine methylol, having a pH in a range of between about 8 and about 10, and having a melamine-to-formaldehyde molar equivalent ratio of between about 1 : 1 and about 1 :3.2.
- the curable resin composition also includes a formaldehyde-based resin, wherein the melamine methylol comprises between about 1 wt% and about 50 w1% of the combined weight of the formaldehyde- based resin and the melamine methylol.
- a method of preparing a curable resin composition that includes an aqueous dispersion of melamine methylol, having a pH in a range of between about 8 and about 10, and having a melamine-to-formaldehyde molar equivalent ratio of between about 1 :1 and about 1 :3.2, is also included in the invention.
- the method includes mixing the aqueous dispersion of melamine methylol with a formaldehyde-based resin, wherein the melamine methylol comprises between about 1 wt% and about 50 wt% of the combined weight of the formaldehyde-based resin and the melamine methylol.
- a further embodiment of the invention is directed to a method of preparing an abrasive product, comprising contacting a plurality of abrasive particles with a curable resin.
- the curable resin includes an aqueous dispersion of melamine methylol, having a pH in a range of between about 8 and about 10, and having a melamine-to- formaldehyde molar equivalent ratio of between about 1:1 and about 1:3.2.
- the curable resin composition also includes a formaldehyde-based resin, wherein the melamine methylol comprises between about 1 wt% and about 50 wt% of the combined weight of the formaldehyde-based resin and the' melamine methylol.
- the curable composition is then cured to produce the abrasive product.
- the invention is directed to a method of abrading a work surface, comprising applying an abrasive product to a work surface in an abrading motion to remove a portion of the work surface.
- the abrasive product includes a plurality of abrasive particles, and a resin binder.
- the resin binder is cured from a resin composition that includes an aqueous; dispersion of melamine methylol, having a pH in a range of between about 8 and aboul 10, and having a melamine -to -formaldehyde molar equivalent ratio of between about 1 :1 and about 1:3.2.
- the resin composition also includes a formaldehyde-based resin, wherein the melamine methylol comprises between about 1 wt% and about 50 wt% of the total weight of the formaldehyde-based resin and the melamine methylol.
- the present invention has many advantages. For example, employing a resin composition, which includes a formaldehyde-based resin and the melamine methylol described above, can significantly reduce the amount of free formaldehyde available to be released during processing of the resin composition. Further, the reduction of free formaldehyde can occur in formaldehyde-based resins, such as urea-formaldehyde resins and phenol-formaldehyde resins, obtained by curing the resin composition. In addition, reduction of free formaldehyde typically can occur without significant diminishment of performance in abrasive products incoiporating a resin binder cured from the resin composition.
- FIG. 1 is a schematic representation of a cross-sectional view of one embodiment of a coated abrasive product of the invention.
- FIG. 2 is a schematic representation of a cross-sectional view of another embodiment of a coated abrasive product of the invention.
- the present invention employs an aqueous dispersion of melamine methylol, having a pH between about 8 and about 10 (e.g., a pH between about 8.5 and about 10), and having a melamine-to-formaldehyde molar equivalent ratio of between about 1 : 1 and about 1 :3.2.
- the melamine methylol is relatively stable with improved hydrolytic and thermal properties.
- Conventional melamine- formaldehyde resins known in the art are generally made from melamine and formaldehyde through a two stage reaction, i.e., formation of methylol (-CH 2 -OH) groups, and condensation reactions (or polymerization reactions) of the methylol groups.
- condensation reactions of the methylol groups of one melamine unit with amine (-NH 2 ) groups or with methylol groups of another melamine unit occur at an acidic or a neutral condition in the presence of a catalyst.
- Condensation between methyol groups of one melamine unit and amine groups of another melamine unit form methylene bridges (-CH 2 -) linking the two different melamine units.
- the melamine methylol employed in the invention is prepared by mixing melamine and formaldehyde in a basic condition (e.g., pH 8.5 - 10) without employing any catalyst, or an acidic or a neutral condition, employed in the conventional melamine-formaldehyde resins for the condensation reaction.
- the melamine methylol formed from the reaction between melamine and formaldehyde is then kept in a basic aqueous medium having a pH of between about 8 and about 10 for subsequent use, e.g., preparing a resin composition that includes a formaldehyde-based resin and the melamine methylol.
- the basic medium prevents extensive condensation reactions that typically occur in conventional melamine-formaldehyde resins. Also, without being bound to any particular theory, it is believed that, in the melamine methylol employed in the invention, the methylol groups that have not gone through condensation reaction are thus available for scavenging of free formaldehyde in formaldehyde-based resins, such as urea-formaldehyde and phenol-formaldehyde resins.
- the melamine methylol aqueous dispersion includes a.t least about 10 wt% free melamine methylol and low-condensed melamime methylol on the basis of the total weight of the melamine and formaldehyde used to make the melamine methylol dispersion.
- "Free" melamine methylol means a melamine-formaldehyde product that is not linked to another melamine-formaldehyde product. Free melamine methylol encompasses compounds represented by the following structural formula:
- each Q is independently -NH 2 , -NH-CH 2 OH or -N(CH 2 OH) 2 and at least one of the three Qs is either -NH-CH 2 OH or -N(CH 2 OH) 2 .
- "Low-condensed" melamine methylol means a melamine-formaldehyde product that has a limited number of melamine units that are linked together via either methylene linkages or dimethylene ether bridges, wherein the limited number is less than 50.
- the melamine methylol aqueous dispersion includes at least about 20 wt%, more preferably at least about 35 wt%, even more preferably at least about 50 wt%, of free and low-condensed melamine methylol on the basis of the total weight of the melamine and formaldehyde used to make the melamine methylol dispersion.
- the aqueous dispersion of melamine methylol employed in the invention is prepared by mixing an aqueous solution of formaldehyde, with melamine in an aqueous medium in a suitable reactor, such as a reactor equipped with an agitator and a condenser.
- the melamine-to-formaldehyde mol ⁇ ir ratio of the mixture is in a range of between about 1 : 1 and 1 :3.2
- the aqueous solution of formaldehyde has adjusted to a pH of between about 8 and about 10, for example by adding NaOH, and includes equal to or less than about 6 wt% of methanol based on the total weight of the formaldehyde solution.
- the aqueous medium of melamine has a pH of between about 7.5 and about 10, preferably a pH of between about 8.5 and aboutlO, more preferably a pH between about 9 and about 10, and even more preferably about pH 9.
- the aqueous formaldehyde solution is formalin, and includes about 37.5% by weight formaldehyde.
- methanol is added to the formaldehyde solution to stabilize the formaldehyde and avoid the formation of para-formaldehyde.
- the amount of methanol in the aqueous solution is in a range of between about lwt. % and about 10 wt. % methanol, for example, about 6 wt. %, or about 3 wt. % methanol.
- the pH of the mixture of melamine and formaldehyde is adjusted to have a pH of between about 8 and about 10 by addition of any suitable basic solution, such as a solution of NaOH (e.g., 2N NaOH solution).
- a suitable basic solution such as a solution of NaOH (e.g., 2N NaOH solution).
- the pH of the mixture of melamine and formaldehyde is adjusted to have a pH of between about 8.5 and about 10, such as between about 8.5 and about 9.5 or between about 9 and about 10.
- the reaction mixture is then he ⁇ iled to a suitable temperature for a period of time sufficient to cause the melamine to dissolve all or a substantial portion of the added melamine.
- the reaction mixture is maintained at a temperature in a range of between about 85° C and about 95 0 C for a period of time, for example, between about three hours and about 10 hours (e.g., between about 4 hours and about 7 hours, or between about 4.5 hours and about 6.75 hours), En another more specific embodiment, the reaction mixture is maintained at a temperature about 90 0 C for a period of time, for example, about 6 hours and 45 minutes, to dissolve all or a substantial portion of the added melamine.
- the temperature of the reaction mixture generally is maintained at a temperature within a range of 1 0 C.
- the melamine methylol has ai melamine-to-formaldehyde molar ratio of between about 1:1 and 1 :3.2, such as about 1 :1.6, about 1 :1.7 or about 1:2.
- the melamine-to-formaldehyde molar ratio of the melamine methylol is in a range of between about 1 : 1 and about 1:2, more specifically between about 1:1.5 and about 1 :2.
- the pH of the melamine methylol dispersion is in a range of between about 8 and about 10.
- the pH is in a range of between about 8.0 and about 9. More preferably, the pH is in a range of between about 8.2 and about 8.8. Even more preferably, the pH is about 8.5.
- the solid content of the melamine methylol dispersion is less than about 65 wt% based on the total weight of the melamine methylol aqueous dispersion.
- the solid content is in a range of between about 30 wt% and about 65 wt%. Even more preferably, the solid content is in a range of between about 45 wt% and about 65 wt%, or of between about 50 wt% and about 60 wt%, such as about 59 wt%.
- the viscosity of the melamine methylol aqueous dispersion can be adjusted depending upon particular uses of the dispersion.
- the melamine methylol aqueous dispersion has a viscosity of between about 50 cps and about 800 cps at about
- the viscosity is in a range of between about 100 cps and about
- the melamine methylol dispersion employed in the invention has a viscosity is about 300 cps, a solid content of about 59% by weight, and a pH of about 8.5.
- the curable resin composition of the invention includes the aqueous dispersion of melamine methylol described above and a fo ⁇ naldehyde-based resin.
- the melamine methylol comprises between about 1 wt% and about 50 wt% of the combined weight of the formadehyde-based resin and the melamine methylol.
- the melamine methylol content corresponds to the total amount, in weight, of melamine and formaldehyde that are used for making the melamine methylol aqueous dispersion.
- the melamine methylol comprises between about 5 wt% and about 30 wt% of the combined weight of the formaldehyde-based resin and the melamine methylol.
- the melamine methylol comprises between about 5 wt% and about 20 wt% of the combined weight of the formaldehyde-based resin and the melamine methylol. In yet another specific embodiment, the melamine methylol comprises between about 8 wt% and about 13 wt% of the combined weight of the formaldehyde-based resin and the melamine methylol.
- the features, including preferred features, of the melamine methylol dispersion are as described above.
- the resin composition includes an aqueous dispersion of melamine methylol having a melamine- to-formaldehyde molar equivalent ratio of between about 1:1 and about 1 :3.2, preferably between about 1 : 1 and about 1 :2, wherein the aqueous dispersion has a pH in a range of between about 8.2 and about 9.
- the resin composition includes a formaldehyde -based resin, wherein the melamine methylol comprises between about 1 wt% and about 50 wt% (e.g., between about 10 wt% and about 50 wt% or between about 10 wt% and about 30 wt%, preferably between about 5 wt% and about 20 wt%, between about 5 wt% and about 10 wt%, or between about 8 wt% and about 13 wl%) of the combined weight of the formaldehyde-based resin and the melamine methylol.
- the melamine methylol comprises between about 1 wt% and about 50 wt% (e.g., between about 10 wt% and about 50 wt% or between about 10 wt% and about 30 wt%, preferably between about 5 wt% and about 20 wt%, between about 5 wt% and about 10 wt%, or between about 8 wt% and about 13 w
- the melamine methylol dispersion has a solid content in a range of between 45 wt% and about 65 wt%, and a viscosity of between about 100 cps and about 500 cps at about 25 °C.
- the melamine methylol aqueous dispersion tias a solid content in a range of between 45 wt% and about 65 wt%, and a viscosity of between about 250 cps and about 350 cps a1 about 25 0 C.
- the resin composition in another embodiment, includes an aqueous dispersion of melamine methylol having a melamine-to-formaldehyde molar equivalent ratio of between about 1:1 and about 1 :3.2, preferably between about 1 : 1 and about 1 :2, wherein the aqueous dispersion has a pH in a range of between aibout 8.2 and about 8.8, such as 8.5.
- the resin composition includes a formaldehyde-based resin, wherein the melamine methylol comprises between about 1 wt% and about 50 wt%, preferably between about 5 wt% and about 20 wt% or between about 5 wt% and about 10 wt%, of the combined weight of the formaldehyde-based resin and the melamine methylol.
- the melamine methylol dispersion has a solid content in a range of between 45 wt% and about 65 wt%, and a viscosity of between about 250 cps and about 350 cps at about 25 0 C.
- the resin composition includes an aqueous melamine methylol dispersion having a viscosity of between about 250 cps and about 350 cps at about 25 0 C, a solid content in a range of between about 45 w1% and about 65 wt%, and a pH of between about 8.2 and about 8.8.
- the melamine methylol comprises between about 10 wt% and about 20 wt% of the total weight of the combined weight of the formaldehyde- based resin and the melamine methylol.
- the pH of the melamine methylol dispersion is about 8.5.
- the melamine-to- formaldehyde molar equivalent ratio is preferably between about 1 :1.5 and about 1 :2.
- the solid content is preferably about 59 wt%.
- a "formaldehyde-based resin,” as used herein, means a resin product produced from polymerization of formaldehyde with any suitable counter reactant.
- suitable counter reactants includes organic molecules having at least one functional groups selected from the group consisting of -OH, -SH and -NHj Specific examples include phenol compounds having at least one -OH group, and urea.
- the formaldehyde-based resin is a phenol-formaldehyde resin or a urea- formaldehyde resin. Any suitable commercially available phenol -formaldehyde resins and urea-formaldehyde resins can be used hi the invention.
- an uncured or uncrosslink ⁇ d “resin” is a composition for curing or crosslinking, comprising one or more components selected from monomers, oligomers, and polymers, and may opiionally contain other additives such as coloiants, stabilizers, plasticizers, fillers, solvents, antiloading agents, or the like.
- a resin includes a mixture of partially polymerized components that harden upon curing, which is typically the result of a crosslinking reaction.
- the uncured or uncrosslinked resin can be cured by initiation wit Ii light, electron beam radiation, acid, base, heat, combinations thereof.
- the curable resin composition of the invention can be used for a resin binder employed in abrasive products, such as bonded abrasive product (e.g., abrasive wheels, disks and horns) and coated abrasive products (e.g., abrasive films and papers).
- abrasive product of the invention includes a plurality of abrasive particles and a resin binder cured from the resin composition described above.
- the resin composition can be blended with a plurality of abrasive particles or, in the alternative, applied over abrasive particles and then cured to form a make coat or a size coat over a base layer and the plurality of abrasive particles of an abrasive product. After application of the resin composition, either as a bond, a make coat or a size coat, the resin composition is cured under any suitable condition known in the art.
- the abrasive product of the invention is a coated abrasive product that includes a base layer, a plurality of abrasive particles, and a resin coat attaching the plurality of abrasive particles to the base layer.
- the resin coat is cured from a resin composition as described above.
- the abrasive product of the invention is a bonded abrasive product that includes a plurality of abrasive powders and a resin binder cured from a resin composition as described above. In the bonded abrasive product, the abrasive powders are typically bonded together with the resin binder.
- the cured resin binder has a formaldehyde emission less than about 300 micrograms/m 3 per hour, as determined by the standard climatic chamber test procedure (e.g., "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers,": dhs.ca.gov/ps/deodc/elilb/iaq/VOCS/Section_01350_reface.htm) that follows the guidance of ASTM (American Society for Testing and Materials) 5116-97, " Standard Guide for Small-Scale Environmental Chamber Determinations of Organic Emissions for Indoor Materials/Products.”
- the coated abrasive product of the invention generally include a substrate (i.e., base layer), an abrasive particles and at least one binder to hold the abrasive material to the substrate.
- coated abrasive product encompasses a nonwoven abrasive product.
- the abrasive material such as abrasive grains, particles or agglomerate thereof, can be present in one layer (e.g., resin-abrasive layer) or in two layers (e.g., make coat and size coat) of the coated abrasive tools.
- FIGs. 1 and 2 show coated abrasive products 10 and 30 of the invention. Referring to FIG. 1, in coated abrasive product 10, substrate 12 is treated with optional backsize coat 16 and optional presize coat 18. Overlaying the optional presize coat 18 is make coat 20 to which abrasive material 14, such as abrasive grains or particles, are applied.
- Size coat 22 is optionally applied over make coat 20 and abrasive particles 14. Overlaying size coat 22 is optional supersize coat 24. Depending upon their specific applications, coated abrasive product 10 may or may not include backsize coat 16 and/or presize coat 18. Also, depending upon their specific applications, coated abrasive product 10 may or may not include size coat 22 and/or supersize coat 24. Shown in FIG. 2 is coated abrasive product 30 that includes a single layer of an abrasive material and adhesive(s) (binder-abrasive layer 32) and optionally backsize coat 16. Optionally, presize coat 18, size coat 22 and supersize coat 24, as shown in FIG. 1, can be included in coated abrasive tools 30.
- a curable resin composition of the invention is used in forming at least one layer selected from the group consisting of binder-abrasive layer 32, backsize coat 16, presize coat 18, make coat 20, size coat 22 and supersize coat 24.
- a curable resin composition of the invention is used in forming at least one adhesive layer selected from the group consisting of presize coat 18, make coat 20 and size coat 22.
- a curable resin composition of the invention is used to form a binder for affixing abrasive particles 14 to substrate 12, for example, for forming binder-abrasive layer 32 or at least one coat of coats 20 (make coat) and 22 (size coat).
- a curable resin composition of the invention is used to form a binder for binder-abrasive layer 32.
- abrasive particles 14 can be applied separately by gravity, electrostatic deposition or in air stream, or as slm ⁇ y together with the curable resin composition.
- Substrate 12 may be impregnated either with a resin-abrasive slurry or a resin binder without abrasive grains, depending upon the required aggressiveness of the finished coated abrasive tools, as described above.
- Substrate 12 useful in the invention can be rigid, but generally is flexible.
- Substrate 12 can be paper, cloth, film, fiber, polymeric materials, nonwoven materials, vulcanized rubber or fiber, etc., or a combination of one or more of these materials, or treated versions thereof.
- the choice of the substrate material generally depends on the intended application of the coated abrasive tool to be formed. In a preferred embodiment, substrate 12 is a nonwoven material.
- nonwoven means a web of random or directional fibers held together mechanically, chemicalty, or physically, or any combination of these.
- nonwoven materials include fibers formed into a nonwoven web that provides as a three-dimensional integrated network structure. Any fibers known to be useful in nonwoven abrasive tools cat ⁇ be employed in the invention. Such fibers are generally formed from various polymers, including polyamides, polyesters, polypropylene, polyethylene and various copolymers thereof. Cotton, wool, blast fibers and various animal hairs can also be used for forming nonwoven fibers.
- the nonwoven substrate can include a collection of loose fibers, to which abrasive particles 14 are added to provide an abrasive web having abrasive particles 14 throughout.
- abrasive particles 14 are applied over a substrate prior to, after and/or simultaneously with the application of a curable resin composition as described above to the substrate.
- Abrasive particles 14 can be applied over substrate 12 by spraying (via gravity, electrostatic deposition or air stream) or coating with the curable resin composition.
- abrasive particles 14 are applied over substrate 12 simult ⁇ ineously with the curable resin composition. In one example of this embodiment, as shown in FIG.
- the curable resin composition and abrasive material are mixed together to form a binder-abrasive composition slurry, and the slurry is applied over substrate 12 to form single binder-abrasive composition layer 32.
- abrasive particles 14 is applied over a substrate coated with the curable resin composition.
- the curable resin composition is used for forming at least one of the backsize, presize and make coats.
- abrasive particles 14 are applied prior to the application of the curable resin composition to substrate 12.
- the curable resin composition is uss-;d for forming at least one of the size and supersize coats.
- Abrasive particle materials 14 useful in the invention can be of any conventional abrasive particle material utilized in the formation of coated abrasive tools.
- suitable abrasive particle materials for use in the invention include diamond, corundum, emery, garnet, chert, quartz, sandstone, chalcedony, flint, quartzite, silica, feldspar, pumice and talc, boron carbide, cubic boron nitride, fused alumina, ceramic aluminum oxide, heat treated aluminum oxide, alumina zirconia, glass, silicon carbide, iron oxides, tantalum carbide, cerium oxide, tin oxide, titanium carbide, synthetic diamond, manganese dioxide, zirconium oxide, and silicon nitride.
- the abrasive materials can be oriented or can be applied to the substrate without orientation (i.e., randomly), depending upon the particular desired properties of the coated abrasive tools. In choosing an appropriate abrasive material, characteristics, such as size, hardness, compatibility with workpieces and heat conductivity, are generally considered.
- Abrasive particle materials useful in the invention typically have a particle size ranging from about 0.1 micrometer and about 1,500 micrometers, such as from about 10 micrometers to about 1000 micrometers.
- the adhesive layer(s) of coated abrasive tools 10 and 30 can be made by any suitable method generally known in the art.
- optional backsize coat 16 and optional presize coat 18, not containing abrasive particles 14, are coated on substrate 12 and cured by exposure to heat in order to impart sufficient strength to substrate 12 for further processing.
- make coat 20 is applied to substrate 12 to secure abrasive particles 14 throughout substrate 12, and while the coat is still tacky, abrasive particles 14 are applied over make coat 20.
- the make coat is subsequently cured so as to hold abrasive particles 14 in place.
- size coat 22 is applied over substrate 12, and then cured.
- size coat 22 generally is to anchor abrasive particles 14 in place and allow them to abrade a workpiece without being pulled from the coated abrasive structure before their grinding capability has been exhausted.
- a slurry of abrasive particles 14 and a resin binder composition described above is applied over substrate 12, optionally on presize coat 18 over substrate 12, and then cured.
- supersize coat 24 is deposited over size coat 22.
- Supersize coat 24 can be deposited with or without a binder, as described above.
- the function of supersize coat 24 is to place on a surface of coated abrasive materials 14 an additive that provides special characteristics, such as enhanced grinding capability, surface lubrication, anti-static properties or anti-loading properties.
- suitable grinding aids include KlBF 4 and calcium carbonate.
- suitable lubricants for supersize coat 24 include lithium stearate.
- suitable anti- static agent include alkali metal sulfonates, tertiary amines and the like.
- Suitable anti-loading agents include metal salts of fatty acids, for example, zinc stearate, calcium stearate and lithium stearate, sodium laurel sulfate and the like.
- Anionic organic surfactants can also be used effective anti-loading agents.
- anionic surfactants and antiloading compositions including such an anionic surfactant are described in U. S. Patent Application Publication No.
- anti-loading agents include inorganic anti-loading agents, such as metal silicates, silicas, metal carbonates, metal sulfates. Examples of such inorganic anti-loading agents can be found in WO 02/062531, the entire teachings of which are incorporated herein by reference.
- the coated abrasive product of the invention includes a nonwoven substrate, such as a nonwoven substrate made from an air-laid process which is well known in the ait.
- the nonwoven substrate Is impregnated with a coating composition escribed above, and an abrasive material, such as fine abrasive particles.
- the uncured, impregnated nonwoven substrate is wound spirally to form a log.
- the uncured impregnated nonwoven substrate is cut into sheets and the sheets are stacked between two metal plates to form a slab.
- the log or slab is then heated to form the nonwoven abrasive tool.
- the cured log or slab is converted into a final shape normally used for polishing, deburring, or finishing applications in the metal or wood Industries.
- the curable resin composition of the invention can optionally further include one or more additives, such as fillers, coupling agents, fibers, lubricants, surfactants, pigments, dyes, wetting agents, grinding aids, anti-loading agents, anti-static agents and suspending agents.
- additives such as fillers, coupling agents, fibers, lubricants, surfactants, pigments, dyes, wetting agents, grinding aids, anti-loading agents, anti-static agents and suspending agents.
- Specific additive(s) that is included in the resin composition can be chosen depending upon for which adhesive layer(s) (e.g., coats 16, 18, 20, 22, 24 and 32 of FIGs. 1 and 2) the resin composition is employed.
- supersize coat 24 can include one or more anti-loading agents.
- One or more grinding aids can be included in size coat 22 and/or make coat 20. The amounts of these materials are selected, depending upon desired properties to achieve.
- the abrasive product of the invention can generally take the form of sheets, discs, belts, bands, and the like, which can be further adapted to be mounted on pulleys, wheels, or drums.
- the coated abrasive product of the invention can be used for sanding, grinding or polishing various surfaces of, for example, steel and other metals, wood, wood-like laminates, plastics, fiberglass, leather or ceramics.
- the abrasive product of the invention is used for abrading a work surface by applying the abrasive product in an abrading motion to remove a portion of the work surface.
- Example 1 Preparation of Aqueous Dispersion of Liquid Melamine Methylol (LMM)
- LMM Liquid Melamine Methylol
- the melamine methylol was made by a batch process in a three necked round bottom flak (reaction kettle) equipped with an agitator and a condenser. Specified amount of melamine and formaldehyde were charged into the flask in the desired molar ratio.
- LMM aqueous dispersion having a nielamine-to-formaldehyde molar ratio of 1 : 1.6 was prepared as follows:
- melamine and formaldehyde were used.
- a 37.5% aqueous solution of formaldehyde was used.
- the formaldehyde solution included about 4-6 wt% methanol.
- the formaldehyde solution was adjusted to have a pH about 9 using a 2N NaOH solution.
- About 75O g of melamine, and 761.9 g of formaldehyde in a 37.5 % formaldehyde solution were added to the reaction kettle.
- 112.6 mL of water having pH 11 (adjusted with 2 N NaOH) was also added to the reaction kettle to make the reaction mixture at a highly basic medium. The temperature of the reaction mixture was controlled using a water bath.
- the set temperature of the water bath was varied from 50 0 C to 95 0 C by step by step by watching the temperature of the reaction kettle.
- the reactor temperature was maintained at 90 0 C for 6 hours and 45 minutes to get melamine dissolved.
- the formed LMM aqueous dispersion has a viscosity of 300 cps at 25 0 C, a solid content of 59 % and a pH of 8.5. No free formaldehyde was detected from the LMM aqueous dispersion.
- LMM aqueous dispersion having a melamine-to-formaldehyde molar ratio of 1 :1.7 and 1:2.0 were also prepared using similar process described above for the LMM having having a melamine-to-formaldehyde molar ratio of 1 : 1.6.
- Urea-formaldehyde (UF) resi ⁇ and phenol-formaldehyde (PF) resin which were purchased from West Coast Polymer PVT, Ltd., were used in the example.
- the specification of the UF and PF resins are as follows:
- LMMs having various molar ratio of melamine and formaldehyde were prepared using the processes described in Example 1. Each of the liquid LMMs was blended with the liquid UF or PF resin by using laboratory stirrer which have a regulator for controlling rpm and it can be varied from 100 rpm -1000 rpm by adjusting regulator . The loading of liquid LMM was based on weight percentage. The mixture was then poured into an aluminum foil for getting thin film and cured at 105 0 C for 2 hours. These cured samples were ground to less than 25 mesh by using mortar and pestle and samples were taken for hydro lytic stability study.
- Free formaldehyde (HCHO) emission of the samples under a hydrolytic condition at 60 0 C for 3 hours were measured.
- free formaldehyde emission tests freshly cured resins were used.
- a portion of the freshly cured resins (2gm) was grounded to less; than 25 mesh.
- the grounded resin was suspended in 100-ml distilled water (pH 7) and maintained at 60 0 C under continuous stirring in a flask. The suspension was then filtered, and the filtrate was analyzed for formaldehyde by the sulfite procedure.
- the sulfite procedure was based on chemistry between formaldehyde and Na 2 SO 3 , as shown in the following:
- the free formaldehyde liberation decreased with increasing MF methylol loading.
- the reduction of free formaldehyde liberation was generally related to the mole ratio of formaldehyde (F) and melamine (M) of the LMM used for the study.
- F formaldehyde
- M melamine
- the LMM having a relatively lower F/M mole ratio can quench any available formaldehyde in UF resin having a relatively higher F/M ratio.
- the condensation of the LMM with formaldehyde in the UF resin can provide hydrolytically stable structure to the UF resin.
- Example 3 Abrasive Products Employing Resin Binder Cured from the Liquid LMM
- the make coat and size coat formulations included liquid melamine methylol (LMM) having a F/M molar ratio of 1 : 1.6, which was prepared as described in Example 1.
- the formulations further included a commercially available UF resin (West Coast Polymer PVT, Ltd.), and the amount of the LMM was 10 wt% of the combined weight of the UF resin and the LMM:
- Snow-white filler (Calcium sulphate or Gypsum): 872.96gm Acid catalyst: 118.723 gm (25% soln) Buffer solution :17.45gm Silane : 17.45gm
- Snow-white filler (Calcium sulphate or Gypsum): 874.64gm
- the above make formulation was coated on Awt paper. After application of abrasive particles (aluminum oxide grains, grit size :80# ) onto the make coat, the make coat was cured stepwise at 60 0 C for 1 A hours, at 70 0 C for about 1 A hours and at 95 0 C for about 1 A hours. After curing the make coat, the size coat was applied over the abrasive particles, and then cured at 75 0 C for about 10 minutes and at 65 0 C for about 40 minutes. The cured sample was undergone post curing at 60 0 C for about 8 hours.
- abrasive particles aluminum oxide grains, grit size :80#
- Another sample employing a UF resin and 20 wt% of LMM was prepared using similar procedures to those for the sample employing 10 wt% LMM.
- a control sample employing only the UF resin was also prepared similarly.
- Formaldehyde emission of the samples was measures using the standard climatic chamber test procedure (e.g., "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Environmental Chambers,": dhs.ca.gov/ ⁇ s/deodc/ehlb/iaq/VOCS/Section_01350_reface.htm) that follows the guidance of ASTM (American Society for Testing and Materials) 5116-97, " Standard Guide for Small-Scale Environmental Chamber Determinations of Organic Emissions form Indoor Materials/Products.” The results are summarized in Table 2 below.
- ASTM American Society for Testing and Materials
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- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Polishing Bodies And Polishing Tools (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Phenolic Resins Or Amino Resins (AREA)
Abstract
Description
Claims
Priority Applications (9)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA2699943A CA2699943C (en) | 2007-09-21 | 2008-09-19 | Melamine methylol for abrasive products |
BRPI0817221A BRPI0817221A2 (en) | 2007-09-21 | 2008-09-19 | melamine methiolol for abrasive products |
EP08831944.7A EP2203507B1 (en) | 2007-09-21 | 2008-09-19 | Melamine methylol for abrasive products |
MX2010002535A MX2010002535A (en) | 2007-09-21 | 2008-09-19 | Melamine methylol for abrasive products. |
JP2010524266A JP2010537844A (en) | 2007-09-21 | 2008-09-19 | Melamine methylol for abrasive products |
AU2008302178A AU2008302178B2 (en) | 2007-09-21 | 2008-09-19 | Melamine methylol for abrasive products |
CN2008801060411A CN101796116B (en) | 2007-09-21 | 2008-09-19 | Melamine methylol for abrasive products |
KR1020107007075A KR101168674B1 (en) | 2007-09-21 | 2008-09-19 | Melamine methylol for abrasive products |
ZA2010/02141A ZA201002141B (en) | 2007-09-21 | 2010-03-25 | Melamine methylol for abrasive products |
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US99483007P | 2007-09-21 | 2007-09-21 | |
US60/994,830 | 2007-09-21 |
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WO2009039386A1 true WO2009039386A1 (en) | 2009-03-26 |
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PCT/US2008/077036 WO2009039386A1 (en) | 2007-09-21 | 2008-09-19 | Melamine methylol for abrasive products |
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US (1) | US8979957B2 (en) |
EP (1) | EP2203507B1 (en) |
JP (1) | JP2010537844A (en) |
KR (1) | KR101168674B1 (en) |
CN (1) | CN101796116B (en) |
AR (1) | AR068500A1 (en) |
AU (1) | AU2008302178B2 (en) |
BR (1) | BRPI0817221A2 (en) |
CA (1) | CA2699943C (en) |
CL (1) | CL2008002807A1 (en) |
MX (1) | MX2010002535A (en) |
TW (1) | TW200927899A (en) |
WO (1) | WO2009039386A1 (en) |
ZA (1) | ZA201002141B (en) |
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US8979957B2 (en) | 2007-09-21 | 2015-03-17 | Saint-Gobain Abrasives, Inc. | Melamine methylol for abrasive products |
EP3179894A4 (en) * | 2014-08-13 | 2018-02-28 | Saint-Gobain Abrasives, Inc. | Nonwoven antimicrobial scrub pad |
EP3408342A4 (en) * | 2016-01-25 | 2019-10-30 | Cabot Microelectronics Corporation | Polishing composition comprising cationic polymer additive |
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CN104562689A (en) * | 2013-10-16 | 2015-04-29 | 圣戈班磨料磨具有限公司 | Backing material treated by amino resin, coated abrasive tool product containing and utilizing backing material as well as preparation method of backing material |
KR101720642B1 (en) * | 2015-11-03 | 2017-03-28 | 한가람화학 주식회사 | High-gloss aluminum abrasive chemical composition |
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EP3408342A4 (en) * | 2016-01-25 | 2019-10-30 | Cabot Microelectronics Corporation | Polishing composition comprising cationic polymer additive |
Also Published As
Publication number | Publication date |
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CN101796116B (en) | 2013-04-24 |
KR101168674B1 (en) | 2012-07-25 |
AR068500A1 (en) | 2009-11-18 |
CN101796116A (en) | 2010-08-04 |
US8979957B2 (en) | 2015-03-17 |
EP2203507B1 (en) | 2013-07-03 |
MX2010002535A (en) | 2010-07-02 |
JP2010537844A (en) | 2010-12-09 |
US20090098805A1 (en) | 2009-04-16 |
CA2699943A1 (en) | 2009-03-26 |
AU2008302178A1 (en) | 2009-03-26 |
ZA201002141B (en) | 2011-06-29 |
TW200927899A (en) | 2009-07-01 |
CL2008002807A1 (en) | 2009-08-07 |
CA2699943C (en) | 2013-05-28 |
EP2203507A1 (en) | 2010-07-07 |
AU2008302178B2 (en) | 2012-01-12 |
KR20100065352A (en) | 2010-06-16 |
BRPI0817221A2 (en) | 2015-10-13 |
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